Yamuna vihar - Mukundpur corridor will be the longest line in third phase of Delhi MTRS. It will connect the major stations (Rajori garden, dhaula kuan, anand vihar, and lajpat nagar) There will total 37 stations for which this line will cover 55. Kilometers. Traffic of Delhi is increasing at the rate of more than 6.21% per annum and has resulted in congestion in the traffic and pollution.
Yamuna vihar - Mukundpur corridor will be the longest line in third phase of Delhi MTRS. It will connect the major stations (Rajori garden, dhaula kuan, anand vihar, and lajpat nagar) There will total 37 stations for which this line will cover 55. Kilometers. Traffic of Delhi is increasing at the rate of more than 6.21% per annum and has resulted in congestion in the traffic and pollution.
Yamuna vihar - Mukundpur corridor will be the longest line in third phase of Delhi MTRS. It will connect the major stations (Rajori garden, dhaula kuan, anand vihar, and lajpat nagar) There will total 37 stations for which this line will cover 55. Kilometers. Traffic of Delhi is increasing at the rate of more than 6.21% per annum and has resulted in congestion in the traffic and pollution.
Yamuna Vihar - Mukundpur corridor (brown line) will be the longest line in third phase of Delhi Metro Rail Corporation Limited and will connect the major stations (Rajori Garden, Dhaula Kuan, Anand Vihar, & Lajpat Nagar ). It is the part of third phase of DMRC for which work pakage (project) name CC 04 has been made for underground station at Azadpur and ramp at Mukundpur. There will total 37 stations for which this line will cover 55.7 kilometers.
NEED FOR THE PROJECT Traffic of Delhi is increasing at the rate of more than 6.21% per annum and has resulted in congestion in the traffic and pollution. After constructing the radial routes in Phase I and phase II phase III is focusing on making radial connectivity for the city. After constructing 65 kilometers in phase-I and 124.63 kilometers network in phase-II, need arise for making radial connectivity by metro. Dividing into packages made the work easy to execute & thus project was finalled. Phase III stations are scheduled for completion in 2016 and phase -IV planned for Delhi MRTS is scheduled to complete in 2021.
OBJECTIVE OF THE PROJECT The main objective of the project is to provide a quality transport system to encourage people to shift from private to public. This will help in solving problems of 1.Rate of accidents 2.Less traveling time 3.save fuel and pollution level by 50%
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GENERAL PROJECT INFORMATION Name of the Contract: DMRC Project -CC-04 Detail of the Project : Design and Construction of Tunnels by shield TBMs by Cut and Cover, underground station at Azadpur by Cut And Cover ethod, ramps at Mukundpur and Shalimar Bagh for underground work on Yamuna Vihar-Mukund Pur corridor of Phase-III of Delhi MTRS. Location:- Azadpur Station Construction , DDA Park, Near Azadpur Metro Station, Yellow Line On Kashmirigate-Jahangirpuri metro route,Newdelhi-110009 Type Of Project:- Infrastructural Client :- DMRC[Delhi Metro Rail Corp. Ltd] Consultant:- GEODATA [Italy] Proof Consultant :- SYSTRA Tender Cost Of Project :- 416.8 Crore Type Of Contract:- Lump Sum Contract [Design Built] Approx Area Of Construction; Starting Date of the Project: 01/07/2012 Time Frame : 43 Months Project Complition Date : 01/02/2016
PROJECT LOCATION DETAL Located in the north part of the national capital territory of Delhi. Proposed work falls on the Yamuna Vihar-Mukund Pur corridor of phase III of Delhi Metro Project. Area of work mostly lies in plain terrain 3
City of Delhi is located at 200m from MSL Delhi falls in Seismic Zone IV
ACCESS TO THE SITE Azadpur site is well connected to the all the possible mode of transportation. 1. Airport ; 16 km 2. Railway; 6 km 3. Road: located on NH 1 4. Metro; below the Azadpur metro station.
CLIMATE CONDITIONS Summer April to June Monsoon June to Mid September Winter November to Mid March Temperature Range : min 1 o C and max 45.8 0 C Rain fall: max 191mm and mean 135mm
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ORGANAZATION BACKGROUD DETAILS CEC ( CONTINENTAL ENGINEERING CORPORATION )TAIWAN Continental Engineering Corporation (CEC) Taiwan is widely recognized as one of Taiwans prominent contractor and developer, excelling in major public and private- sector construction as well as long-term land and community development. CEC is one of only a handful of companies licensed in Taiwan to engage in both construction and development. It was founded in 1945 in Chongqing, China by Mr. Glyn T. H. lng,. CEC has from its beginning participated in projects for national reconstruction, helping to rebuild a country ravaged by eight years of war and unrest. With relocation to Taiwan in 1948, CEC engaged extensively in national infrastructure engineering projects. Over the course of the last half century, CEC has built military installations, factories, power plants, highways, tunnels, bridges and mass-transit systems. In this way, CEC has played an important role in Taiwan's economic growth and development. In addition to infrastructure construction, CEC has successfully completed many important public and private-sector projects, such as hospitals, hotels, office buildings, universities, and other educational and research facilities, and the development of CEC's multi-story condominiums and new residential town communities. The work in each field of endeavor complements and enriches the efforts of CEC in all areas. As an experienced contractor and developer, CEC is able to provide its clients with the highest quality of construction in the most economical way. Given the wide scope of its activities and the technical difficulties often involved in its projects.CEC has established an enviable reputation for technological expertise and innovation. CEC has been responsible for some of the prestigious projects like Taiwan High speed Rail Corporation, MRT(Metro Rapid Transit) for Taipei City besides many Tunnels, Expressways and Bridge Projects.
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ABOUT JOINT VENTURE CEC CICI JV AT A GLANCE CEC International Corporation India Pvt. Ltd. (CICI) is 100% subsidiary of CEC & Member of Continental Holdings. CEC is a Civil Engineering Construction Company operating in the fields of MRTS, Highways, Bridges, High Speed Railway, Townships, SEZs, Real Estate and Environment sectors. Being a socially responsible corporate, CICI works in improving the quality of life of the communities it serves whether it be within the organization, industry or society, we have a strong sense of social responsibility, which is reflected in our values and actions. We are involved with construction of high value projects across segments like MRTS, National Highways, Bridges, Urban Roads, Railways and SEZ projects. The team includes International experts from UK, Spain, Hong Kong, Malaysia, Thailand and Taiwan to deliver International quality standards of project execution in India. CICI works including design stands out as the gateway for Technological and Engineering excellence in Civil Engineering fields with project offices scattered across India with head office based at Delhi, CICI is fully equipped to contribute their expertise and turn vision into reality.Mr. Sunil B. Shindeis is the MD of CICI & CEO of CEC India.
MISSION AND VISION Mission To Build Physical Infrastructure for better living. Vision CICI shall be a professionally managed Indian International company, committed to Total Client Satisfaction. CICI shall be innovative, entrepreneurial and empowered team constantly creating value. CICI shall foster a culture of caring, trust and continuous learning while meeting expectations of employees, stakeholders and society.
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CEC CICI JV Completed The Projects In The Following Areas MRTS HIGHWAYS & BRIDGES RAILWAYS TOWNSHIPS / SEZS BUILDING CONSTRUCTION ENVIRONMENT
1.MRTS MRTS is one of our strongest business area coupled with in-house seasoned experts having extensive knowledge base to construct any kind of complex metro system. CEC CICI JV has built underground Metro tunnels sections using TBM.
2.HIGHWAYS AND BRIDGES Over a period of time Cec cici has acquired skills to manage large number of Highway & Bridge projects simultaneously with the help of large pool of in-house experts. Cec has constructed high value highways & expressways with complex geological condition
3.RAILWAYS Cec cici jv have a strong history of developing & executing high value Railway projects. Company has been the biggest investor in Worlds largest Railway BOT project, Taiwan High Speed Rail Corporation (THSRC is a SPV) which is currently valued at US$ 17 billion.
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4.TOWNSHIPS / SEZS CICI is keen to develop Township & SEZ segment in India through investments as well as forging alliances with leading companies. Cec cici jv have recently constructed all the building works for Apache SEZ in Andhra Pradesh and poised to do significantly
5.BUILDING CONSTRUCTION CEC CICI JV have a long experience record of 50 years in Real Estate Development including Office Buildings, Shopping Malls, Hotels, Restaurants, Retail Outlets, Luxury Residential Buildings, High tech Factories, Industrial Buildings, Hospitals, etc.
6.ENVIRONMENT Environment With the success story of Tamsui Sewage BOT Project, we are confident to repeat our experience in Indian market. Over a period of time, we have developed technical & managerial skills to handle complexities of Environment projects.
STANDARDS USED We follow standard operation procedures which allow projects to be certified for ISO 9001, ISO 14001 and OHSAS 18001 for its Quality, Environmental and Occupational Health & Safety Management System.
POSITION OF CEC CEC is one of the top three engineering and construction companies in Taiwan and a leading participant in almost every major infrastructure project in the country.
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CEC CICI IN INDIA In India CEC CICI JV completed many projects with other construction companies. Few of them are following. To meet the ever increasing demand of resources, skill sets, plant & equipment, it becomes necessary to rely on Business Associates.
CEC CICI JV P&M Department at Azadpur site PLANT AND MACHINEARY (P&M) Generally speaking, plant and machinery is an asset that is used by a business for the purpose of carrying on the business and is not stock in trade, the business premises or part of the business premises. The difference between plant and machinery is that generally machinery will have moving working parts, and plant will not (though computers and similar electronic devices are considered to be machinery, despite have no moving parts). The working parts of a machine are also considered to be machinery. Or the place where the maintenance of different devices or equipment are done for their smooth n nonstop working so that it does not go breakdown and the different jobs which are being performed on the site should run continuously.
TYPES OF WORKS IN P&M 1.PREVENTIVE 2.CONDITIONAL
PREVENTIVE:- In this type of work the machine or device is serviced before its breakdown. In general servicing of that device is done after a regular interval. These intervals may be in terms of hours or a certain time. Generally we change or clean the necessary parts or materials depending upon their condition. Like lubricants, filters, grease etc. CONDITIONAL:- In this type the equipment or devices are serviced after break down i.e. the machine goes sudden failure due to failure of any its part or any other reason. Then problems due to which the machine went breakdown are identified and taken the necessary action by the P&M incharge or authorized person.
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RESPONSIBILIES (DUTIES) OF ( P & M ) IN CHARGE To Stop the breakdown at the site or try to minimize the chances of breakdown. Preparation of PR & WR. Procedure followed by a P&M in charge when the breakdown or any problem is reported to the P&M. Go through the problem of the equipment and check the condition of the part. Stick the red label and write Breakdown on that. If it can be modified then consult to the senior mechanic. If it is use useless then refer the catalogue and look for the part number. Ask the store in charge for the same. If it is not available in the store the call the authorized dealer for the same Then prepare the purchase requisition (PR). Then receive the parts through the countersigned by the store incharge Give it to the senior mechanic after confirming the genuine part. After maintenance remove the red label and stick the Green label. Maintain the daily register so that the person coming for the next shift have clear knowledge about that is done in the previous shift and what is to be done ahead and the works under process i.e. current status of any equipment. EQUIPMENT UNDER P&M DEPARTMENT S.No. EQUIPMENTS MODEL/MAKE CAPACITY TPI DATE 01. EXCAVATOR KOBELCO SK210LC 1m 3 02. TIPPER ASHOK LEYLAND 16 TONES 23 APRIL 03. TIPPER ASHOK LEYLAND 16 TONES 23 APRIL 04 CRANE JCB / 3DX 15 TONES 11-MAR 05. EXCAVATOR CAT 06. EXCAVATOR CAT 11
BRIEF DETAILS OF THE PROJECT There will be two tunnel boring machines, namely, EPB TBMs(Earth Pressure Balance Tunnel Boring Machines) both from Herrenknecht which are to be adapted to CC04 project. The EPB machines are shield tunneling machines which is applicable to bore a tunnel through very soft to hard slit layer with an appropriate pressure established in the chamber to avoid the face collapse during the excavation. The EPB machine will be used to construct two twin tunnels running almost parallel between Mukundpur and Azadpur & Azadpur and Shalimar bagh.
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DURATION OF WORK STATION Construction of station is being done by cut and cover method, D-wall type- secant piling Total length=252.415 meters Duration=15 th October 2013 to 05 th October 2014 Flow Chart Station (Bottom to top technique):- Installation of secant piles and capping beam
Excavation for first layer and installation of struts (Repeat this for other layers)
PCC for undercroft
Construction of undercroft
Concourse slab
Box slab
TUNNELS AT SOUTH SHAFT The TBM -01A - (TUNNEL 01)a). For the down line of the tunnel no.1 launched at south shaft Azadpur at the 09 TH January 2014 towards Shalimar Bagh station. The 14
machine will arrive at Shalimar Bagh station on 02 July 2014. Total length = 1448.39 m.Construction of the tunnel=09 th January, 2014 to 17 th July, 2014After that the machine will be Demobilization into six pieces. MACHINE S-780 Demobilization duration-3 rd July, 2014 to 17 th July, 2014
The TBM 02A:- (TUNNEL 02) b). For the up line of the tunnel no.2 TBM launched at the south shaft of Azadpur on 20February 2014 towards Shalimar Bagh station. The machine will arrive at Shalimar Bagh station on 08 Aug 2014. Machine= TBM S-781 Construction of the tunnel =20 Feb 2014 to 08 Aug 2014 Total length=1443.33m After that machine will be Demobilization into six pieces Demobilization duration-09 Aug 14 to 24 Aug 14
TUNNEL AT NORTH SHAFT:- The TBM No 01b Machine- a). For the down line of the at north shaft Azadpur at the 18 Aug 2014 towards Mukundpur ramp area. The machine will arrive at Mukundpur ramp area on 18 Jan 2015. Duration=18 Aug 2014 to 18 Jan 2015 Total length = 1151.31m After that machine will be Demobilization into six pieces Demobilization duration-18 jan 15 to 03 feb 15 15
The TBM No 02B Machine:- a). For the up line of the north shaft Azadpur tbm will be launch at the 24 sep 2014 towards Mukundpur ramp area. The machine will arrive at Mukundpur ramp area on 11 March 2015. Duration=24 September 2014 to 25 February 2015 Total length = 1138.11m Demobilization duration-24 February 15 to 11 March 15 CUT AND COVER TUNNEL (Before Ramp) Upline-79.90m Down Line-94.96m Duration of Construction-13 January 2014 to 23 October 2014 RAMP(UNDER GROUND RAMP) Upline-209.24m Down Line-194.07m Duration of Construction- 02 April 2013 to 21 May 2015 AVERAGE LENGTH DISCRIPTION DOWN LINE(meter) UPLINE(meter) Total For Bored Tunnel One Way 2,599.694 2,581.1442 Total for station 252.408 252.4172 Total for cut and cover tunnel 79.9 94.958 Total for open ramp 209.240 194.067
TOTAL 3,141.242 3,122.884 Note :- There will be 5 cross passages between both the tunnels and out of five one will be with drainage system. 16
OUR TUNNEL BORING MACHINE & SUPPORTING TEAM GENERAL DETAILS OF TBM A typical Tunnel Boring Machine is combination of mainly following parts-
TUNNEL BORING MACHINE (TBMs) DEFINITION- A tunnel boring machine (TBM) also known as a "mole", is a machine used to excavate tunnels with a circular cross section through a variety of soil and rock strata. They can bore through anything from hard rock to sand. Tunnel diameters can range from a meter (done with micro-TBMs) to 19.25 m to date. Tunnels of less than a meter or so in diameter are typically done using trenchless construction methods or horizontal directional drilling rather than TBMs.
HISTORY The first successful tunneling shield was developed by Sir Marc Isambard Brunel to excavate the Thames Tunnel in 1825. However, this was only the invention of the shield concept and did not involve the construction of a complete tunnel boring machine, the digging still having to be accomplished by the then standard excavation methods. The first boring machine reported to have been built was Henri-Joseph Maus' Mountain Slicer. Commissioned by the King of Sardinia in 1845 to dig the Frjus Rail Tunnel between France and Italy through the Alps, Maus had it built in 1846 in an arms factory near Turin. It consisted of more than 100 percussion drills mounted in the front of a locomotive-sized machine, mechanically power-driven from the entrance of the tunnel. The Revolutions of 1848 affected the funding, and the tunnel was not completed until 10 years later, by using less innovative and less expensive methods such as pneumatic drills. In the United States, the first boring machine to have been built was used in 1853 during the construction of the Hoosac Tunnel. Made of cast iron, it was known as Wilson's Patented Stone-Cutting Machine, after inventor Charles Wilson.It drilled 10 feet into the rock before breaking down. The tunnel was eventually completed more than 20 years later, and as with the Frjus Rail Tunnel, by using less ambitious methods. The first successful use was on the Oahe Dam in 1952 by James S Robbins.
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DISCRIPTION Modern TBMs typically consist of the rotating cutting wheel, called a cutter head, followed by a main bearing, a thrust system and trailing support mechanisms. The type of machine used depends on the particular geology of the project, the amount of ground water present and other factors.
USE- Tunnel boring machines are used as an alternative to drilling and blasting (D&B) methods in rock and conventional "hand mining" in soil. TBMs have the advantages of limiting the disturbance to the surrounding ground and producing a smooth tunnel wall. This significantly reduces the cost of lining the tunnel, and makes them suitable to use in heavily urbanized areas. The major disadvantage is the upfront cost. TBMs are expensive to construct, and can be difficult to transport. However, as modern tunnels become longer, the cost of tunnel boring machines versus drill and blast is actually lessthis is because tunneling with TBMs is much more efficient and results in a shorter project. AREA OF APPILACATION OF TUNNELING
1.Tunneling 2.Mining 3.Exploration 1A). Tunneling for Traffic 1B). Tunneling for Utilities a). Metros a). Sewage b). Railways b). Water c). Roads c). Hydropower d). Persons d)Electricity 2). Application in Mining 3. Application in Exploration a). Mining a).Geothermal Energy b).Oil and Gas 19
TBM PARTS DISCRIPTION CUTTER HEAD Cutter head is the front part of any tunnel boring machine, it has specified number of teeth calibrated on it and it has the capability to excavate any kind of soil condition or any type of rock. The cutting wheel is designed &constructed for the specific geologic conditions of site, the one used at Azadpur site has dual mode rim i.e. open & closed. It has wear and tear protection on front face on rim. Main tool used for cutting, these are made up of with inserts tungsten carbide tips and they have sharp edges to cut any type of soil profiles.
FRONT SHIELD- It is the front part of the shield (just behind the cutter head) supports the main drive and screw conveyor and behind this we attach the middle shield. Its diameter is taken as the diameter (average) of the TBMs. The one used at Azadpur site has =6540mm. the space between the cutter head and front shield is called excavation chamber. Here the excavated materials fills and develop the pressure to support the machine and tunnel face profile from collapsing and settlement. Here four numbers of foam connections are provided for soil conditioning.
MIDDLE SHIELD- It is the main part of the TBMs which provides structural support to the TBMs. It consists of almost all the hydraulic and electrical connections. In the middle portion eight numbers of motors are provided to give feed to the main bearing, and this main bearing rotates the cutter head. There are twenty sets of thrust cylinders are provided for the advance the machine which helps the machine to move in the forward direction.
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MAIN LOCK- This part is located in the upper section of the middle shield, the cross passages are provided to go inside the man lock the diameter of the main lock is 600mm. this chamber is filled with the compressed air at the average pressure of 3 bar. The main purpose to provide main lock is to change the cutting tools fitted in the cutter head.
ERECTOR- It has circular ring type structure. Its position in the shield is between the middle shield and tail skin. The main use of the erector is to place the rings in the tunnel to their position. It has six degree of freedoms i.e. its movement can be forward, backward, up, down, right and left(in circular direction).
SCREW CONVEYOR- It fitted to the connecting flange in the pressure bulk head. Main purpose of the screw conveyor is to remove the excavated soil from the excavated soil chamber and deliver it to the conveyor belt. Maximum excavated grain size 300 mm. its capacity is 450m 3/ hour.
TAIL SKIN- It is provided in the last of machine. The ring building takes place in this part of the machine. There are twelve holes are provided in the tail skin four for grouting purpose and eight for the tail skin grease. The triple sealing arrangement is provided in the tail skin for greasing purpose so that outside soil and water does not inter in the shield and tail skin can smoothly slide upon the rings.
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SEGMENT FEEDER- As the name suggests the segment feeders are used to feed the segments to the erector. At the onetime segment feeders can carry three segments (2.85*3=8.55 tones). It can move in four directions forward, backward, up and down. It is operated by hydraulic system by operators, and pulled by the chain of the link diameter 14.25mm.
SCREW BELT- Total length of the screw belt is 45m in length. The main purpose of the screw belt is to deliver the excavated soil in the muck buckets.
LIST OF CONSTITUENT ELEMENTS IN BRIDGE AND GANTRIE 1.BRIDGE Bridge is the first backup which is connected to the TBMs. Its front part is connected to the erector support by means of a hydraulic cylinder. DIMENSIONS WEIGHT Total Length = 12635 ; Support Length=9970 07Tones Total height = 4441 ; from support= 3452 Total Width =4700 ; wheel to wheel =2881
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TABLE FOR :- TBM BRIDGE ACCESSORIES LIST
GANTRY NO.01 & GANTRY NO2 Gantries are connected to the each by means with of of the following 1.Travelling Beams 2.MS Plates 3.Nut bolts S N Lines (hoses of) Side No. of hoses Colour Remarks 1 Water Left 2 Green 2" dia (used for mixing in foam and bentonite) 2 Foam Left 4 Violet 2" dia(Softening the soil condition) 3 Bentonite Left 4 Light yellow 2" dia(to maintain Uniform Profile soil face ) 4 Compress ed Air Left 4 Red 2"dia (Various uses viz ) 5 Grout line Right 4 Brown 2" dia 6 Sodium Silicate Right 4 Black 1" dia
7 Tailseal grease Left 1 Yellow(lower ) 2" dia 8 EP2 grease Left 1 Yellow(upper ) 2"dia 9 Samson unit Left 2 Blue 2"dia (not in use)(maintain the air pressure in chamber) 10 . Hydraulic Right 6 Brown Various dia(for segment feeder) 23
TABLES: LIST OF INSTALLATIONS ON GANTRIES 1 & 2 RESPECTIVELY GANTRY01 S No EQUIPMENTS INSTALLATIONS LOCATION (SIDE) UNITS NOS CAPACITY REMARK 1 Operator cabin Left 1 4-5 person 2 Grout tank Right 1 6 m 3
6 Silicate feed pump Right 4 7 Display Panel Left 1 Grouting S.N O EQUIPMENT (INSTALLATION) LOCATIN (SIDE) UNITS (NOS) CAPACITY REMARK 1. Bentonite tank Left 1 6m 3
2. Foam tank Left 1 1 m 3
3. Hydraulic oil tank Right 1(in 2 parts) 4 m 3
4. Hydraulic Pump no.1 Right 1 315hp(55 IP) Parallel to hyd.oil tank 5. Hydraulic pumpno.2 Right 1 315hp(55 IP) Below hyd.oil tank 6. Hydraulic pump no.3 Right 1 315hp(55 IP) By side of sodium silicate tank 7. Hydraulic pump no.4 Right 1 315hp(55 IP) Below hyd. motor no.1 8. Auxiliary pump Right 1 22hp(126 IP) Below the 24
TABLES: LIST OF INSTALLATIONS ON GANTRIE NO 3 GANTRY03 S. N o. EQUIPMENT NAME LOCATION (SIDE) UNITS (Nos) CAPACITY RAMARKS 0 1. Electrical panels Right 1set 0 2. Lifter crane Left 1 Used to lift grease barrels 0 3. Greasing machines Left 2 0 4. Compressure unit Left 1 0 5 Compressure vessel Left 1 1150 0 6. Ventilation duct above 1 heat exchanger 9. Hydraulic oil cooling system Right 1 Consists of heat exchanger 10. Hyd. Oil Filter Right 1 11. Synchronous Panel Right 1 12. VCB 25
TABLES: LIST OF INSTALLATIONS ON GANTRIE NO 4 GANTRY NO 04:- S. N o. EQUIPMENT NAME LOCATION (SIDE) UNITS (Nos) CAPACITY RAMARKS 0 1. Transformer Right 01 1600 kVA Stepup and stepdown 0 2. Water cooling sys. left 01 0 3 Space for cables right 01 0 4 Ventilation duct Above 01 1000 mm 0 5 Conveyor belt end above 01 0 6 Cable scrollers right 03 0 7 Travelling crane Above(end) 01 1.25 T 0 8. Secondry grouting right 01 2700*1400* 230 Recently joind to the G4
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SUMMURY OF THE TBM & ITS BACKUPS S. N O . NAME OF EQUIP MENT S DIA (MM) LENGTH (MM) MASS (tones)
VOL (m 3 )
1 CUTTE R HEAD 6560 1490/2160 41 52.39
2 FRONT SHIEL D 6540 2850 82 100.78 3 MIDDL E SHIEL D 6530 2955 90 102.14 4 TAIL SKIN 6520 2700 20 S. N O TBM PARTS LENGTH (mm) WIDTH (mm) HEIGHT( mm) VOL (m 3 ) MASS (T) 5 SCRE W CONR. 11900 1220 1405 20.48 20 6 ERECT OR 4250/5295 4000 4000 38.66 25 7 BRIDG E 13320/1281 5 4700/2500 3452 109.38 07 8 GANT RY 10985 4457 4394 109.44 18 27
NO.1 9 GANT RY NO.2 12591 4709 4394 145.92 31 1 0 GANT RY NO.3 10725 4707 4394 121.60 21 1 1 GANT RY NO.4 13837 5033 4808 170.24 25
PRELIMINARY CONSTRUCTION METHODOLOGY FOR TUNNEL LAUNCHIMG SEQUENCE OF EPB TBMs Assembly of a EBM TBMs To assemble of the TBMs, a hydraulic truck mounted crane or a gantry crane with the capacity of more than 400 tones will be used at the location nearby the working shaft EPB TBMs Assembly Process To assemble of the TBM machines, Two hydraulic truck crane are used with the capacity of more than 500T and 150T at the location nearby the south shaft Following are the various steps in which the TBM parts are assembled together to formation of a complete EPB TBM machine STEP-1- In the first step two CRANES of capacities 500 T & 150 T are used to lift down the TBM front shield onto the cradle at the bottom of the south shaft The weight of the front-body is 82 T
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STEP-2 In the second step cutter head of the TBM brought down onto the cradle and In step two also same cranes are used It is connected with the front shield The weight of the cutter head is 41 T
Step 3 29
After that we moved the TBM machine forward STEP-4 In the fourth step the middle-shield is Lower down onto the cradle in the south shaft Then Middle-shield and front-shield are connected together
STEP-5 In the fifth step the erector was lowered down on the cradle in the south shaft Then Erector and middle-shield are connected together STEP-6 In sixth step the screw conveyor lower down onto the cradle in the south shaft Then Screw conveyor and front-shield are connected together
STEP-7 30
In the seventh step the tail skin lower down onto the south Shaft Then Tail skin and middle-body were connected together Note :-Tunnel TBM assembled follow-up of the gantry crane assembly and hydraulic and electrical configuration, after TBM machine test PREPARATION FOR THE INITIAL DRIVE OF TBM
Fig:-TBM just before entering in the tunnel 1.Test the water at TBM launching point i.e. in the south shaft Test the water Qualified Standard it should be K10 -5 cm/sec TBM launching point survey and in survey we generally look for the Surveying and site mapping Points drilling (L= TBM length 2/3) and Drilling =38mm 2.Then TBM launching eye construction The machine (PC120) knockout (piles) of the thickness of 60cm to 65cm It should be noted that whether there is water leakage and sand leakage of situation. Then Launch eye knockout by machinery (PC120) Eye knockout Construction process 3.Launching eye frame Installation, engineer checks the launching Point 31
Coordinates (N, E) and elevation (E.L), Follow-up to flappers and rubber After the completion of the Knockout process We Install Launching box and then we use the iron plate (3mm), the inner patch, upon completion of the launching box wall template Then the assembly and concrete pouring is done After that we installed the sealing Baffles and apron BAFFLES (TUNNEL EYES) DETAILS
4. CRADLE AND REACTION FRAME INSTALLATION After the completion of these work,we install the CRADLE and the REACTION FRAME. Before installation of the cradle and reaction frame we check the base slab elevation upon which the cradle and reaction frame to be installed Note -The cradle and reaction frame must be set to the correct position both line and their elevation.
1).TBM CRADLE Dimensions Space b/w supports(6nos) =1500mm Total 108 (sets) Angle 3.33 degree Distance 3548 mm Length 160mm Thickness 6mm Height 425mm(285+120) Hole Dia 27mm 32
distance b/w rails =3290mm Angle B/W Rails =60 o Rail Mass =30 Kg Each Cradle Base Dimensions =300*305*15*15(mm) Base Length =5830mm Total length =7873mm
Fig : CRADDLE
(2)TBM REACTION FRAME 33
I beam dimensions =621.8,326.5,15.4,24.4(mm) Height =1953+6427(3226+3201)mm Width =6402(3201+3201)mm The distance of the reaction frame from the Secant Pile is 9986mm(3) Reaction frame Workbench and the angle between the main frame and their support is 40 o
Fig:REACTION FRAME Then we proceed for the following works- (1)Breaking and drilling the portion of tunnel eye. (2)Test the seepage in the portion of tunnel eye in 24 hours. Launch eye artificial knockout completed (3)Breaking from bottom to up. 34
(4)Set up temporary ring. 6. STARTING OF TBM INITIAL DRIVE TBM start excavation initially with the help of reaction frame and cradle. All the feed provide to the machine from the surface area and all the power supply via the hydraulic pipes and wires extended, extension of the pipeline construction process is very important work. TBM Beginning excavate Construction TBM is starting by hydraulic jack working against reaction frame. After that when the tunnel length becomes 60 meters or the rings in the tunnel becomes 50 nos the we prepare for the the main drive . 7. Transfer Of Equipment When the TBM excavation completed in the initial drive, We performs the following works * Temporary ring dismantle * Work platforms and rail assembly * Put gantry car system 1. Temporary ring dismantle Temporary ring dismantle process: 35
Step1- In the first step we fix the key segment and taper segment no 2(K & T2) i.e. (1)K and T2 Grouting holes and bolts, fix it then 36
(2)K and T2 dismantling banana bolts Step2- In second step we fix the Taper segment no 2 and then (1)T1 Grouting holes and bolts, using a fixed (2) Dismantling T1 and O1 connection banana bolt step 3- (1)O3 Grouting holes and bolts, using a fixed (2) Dismantling O2 and O3 connection banana bolt Step 4- (1)O1 Grouting holes and bolts, using a fixed (2) Dismantling O2 and O1 connection banana bolt Step 5- (1) The mobile temporary work stand (2)O2 Grouting holes and bolts, using a fixed After dismantling the ring, we proceed for next ring segments And in the last the pipes are installed Pipeline classification Loop drainage (cooling Water out 4) Water in 4 Water out 4 Grouting pipe 3 Grouting pipe 2 8. TBM MAIN DRIVE After completion of the initial drive we proceed for the main drive
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FIG: Tunnel just before the main drive EXCAVATION: The TBM operator and automated system to keep the rate of soil removal equal to rate of machine advance. Additives such as Bentonite, Polymer and Foam are injected into the ground to further stabilize it. Spoil conditioning (polymer, foam and water) will be added to during excavation to primarily aid lubrication and flow of the spoil and as such the quantity added will be dictated by cutter head torque. It will be added to the cutting wheel to the face and within the mixing chamber itself. MUCKING Excavated soil is removed out by the screws conveyor into muck skips which are hauled to the shaft bottom. Soil condition will be added at the excavation chamber as when required to reduce the torque and when in closed mode to aid formation of a plug. Attention as to be paid to the mucking out to detect over-excavation and to the physical appearance and liquidity consistency of the muck to monitor effects of spoil conditioning and changes to the ground condition itself. 38
SEGMENT ERECTION (S,TR,TL) As the TBM advances every 1.2m/ rings consisting of 5(T1,T2,O1 to O3) segments and a key(K) will be built inside the tail skin of the TBM. Table for Segment Lining S.NO. TYPE OF RING LEFT - RIGHT CONFIGURATION 1 Minimum plan metric radius (m) 300 2 Thickness of segmental lining (mm) 27,5 3 Internal diameter (m) 5.80 4 External diameter (m) 6.35 5 Centroid diameter (m) 3.0375 6 Minimum length (mm) 1185 7 Average length (mm) 1200 8 Maximum length (mm) 1215 9 Volume of the biggest segment (m 3 ) 1.26 10 Weight of the biggest segment (kN) 31.5 11 Volume of the ring (m 3 ) 6.3 12 Weight of the ring (kN) 157.5 13 Number of segments per ring 5+1 (key) 14 Number of longitudinal connectors 10 15 Number of bolts for ring 12
TBM OPRATIONAL 39
Once the main drives started it becomes easy to work and the construction for the tunneling work becomes faster. Following sequences for the tunneling 1.Operator of TBM calls to the DG Operator to start four nos DGs (500*4=2000kVA) and here is the list of all the essential switches
Cooling Tower Auxiliary Hyd. Drive Cutting Wheel Drive 1 Ventilation Filter Circuit Cutting Wheel Drive 2 Grease Pump Cutting Wheel 3 Gear Oil Pump copy cutter Erector&Screw Conveyor Thrust Cylinder 2.Cutting wheel pumps 1, 2, & 3 are responsible for the hydraulic oil feed to the hydraulic block situated above the erector. 3.Here 6 hoses from 3 hydraulic pumps delivers the hydraulic oil at an average pressureof 325 bar and this block feeds hyd. Oil to 16 hoses which are responsible to rotate the rexroth motors known as rotary units. There are 8 motors which are responsible to drive the reduction gear box known as main drive, the available power of main drive rotates the cutter head and the cutter head excavate the soil in front of the cutter head. This process is called mining,the soil comes inside the chamber through the cutter head . 4.Here in the chamber because of the soil accumulation pressure increases which is maintains the soil profile in front of the cutter head. 5.When the pressure range lies between 1.5 to 2.5 the screw gate opens and the excavated materials comes out and it falls on the conveyor belt. 6.Conveyor belt delivers material into the muck buckets 7.After filling all (4) muck buckets the locomotive brings these muck cars( muck bucket carriers) outside the tunnel then the operator of gantry cranes pulls these muck buckets from the shaft to the ground level and puts on the muck pits and vacates the muck buckets. This procedure is repeated for next three buckets. 40
8.After appropriate excavation of the soil the ring building started rings are brought inside the tunnel by locomotive,then segment lifter crane liftes these segments one by one and puts on the segment feeder. 9. Erector operator retrieve the thrust cylinders and makes a space for the segment fitting. 10. Erector operator fits the segments according to their specified positions given by the civil department. 11. Then thrust cylinders are expanded to press and again start the excavation process. 12.Simulteniously the grouting is also goes on to fill the vacant space out side the tunnel.Grout(4 m 3 ) comes from the grounting plant in the grout tank(6 m 3 ). 41
TUNNELING PROCEDURE
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13.Here grout operator regulates the grouting, and maintains the liquid A and liquid B propotion. Normally (B=8% of A). 14. The tail seal grease is responsible to stop the scrapes to come inside the shield. There are 8no of hoses inside the tail skin which delivers the TSG in the drain made in the tail skin. Copper wire brush regulates the amount of tail skin grease to apply on the outer surface of the segments(avg TSG per ring=30kg) This procedure repeated for the a complete ring building.
PLANTS AT MUNDKA & MUKUNDPUR 1.MUKUNDPUR Activities and flow charts of Mundpur TUNNEL BY CUT AND COVER METHOD 1.Flow(Method) Chart For Cut And Cover Construction of The D-Wall Excavation Struts and WB Installation Top Slab RAMP 2.Flow(Method) Chart For The Ramp Installayion of the secent walls Capping beab Rewall Filling and back fill as required 43
BATCHING PLANT AT MUKUNDPUR Capacity = 0.5 m 3 /batch; 30 cum
capacity Facilities Available At Mukundpur are Following:- 1.Chiller plant 2.Water softening plant 3.Testing lab FACTORY AT MUNDKA PRECAST SEGMENT YARD:- Total Area = 23600 m 2 Area(segment production ) = 3200 m 2 Area(storage) = 6100 m 2 Production rate =14 rings / day BATCHING PLANT Capacity= 2*0.5 M 3 / Batch
EQUIPMENTS 15 T Gantry Crane 03 T Over Head Crane 10 T Gantry Crane 10 T Vibration Platform
SEGMENT PRODUCTION & STORAGE AT MUNDKA AND SEGMENT TRANSPORTATION TO AZADPUR SITE
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SEGMENT PRODUCTION- Segments are produced at the Mundka pre casting yard in the moulds.
SEGMENT STORAGE YARD After Production Segments Are Stored In The Storage Yard.
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TRANSPORTATION OF SEGMENTS (from Mundka to Azadpur job site)
As per the requirements of the rings it is transported here at Azadpur site by trailers the total weight of 3 sets is 48.18 tones. 500mm 500mm 3 0 0 m m 3586 T2 T1 K O1 O3 O1 O3 O1+O2+O3=?t 3.21+3.21+3.21=9.63t T1+T2+K=?t 2.88+2.88+0.67=6.43t T1+T2+K=?t 2.88+2.88+0.67=6.43t O1+O2+O3=?t 3.21+3.21+3.21=9.63t O1+O2+O3=?t 3.21+3.21+3.21=9.63t T1+T2+K=?t 2.88+2.88+0.67=6.43t Transport:40 ft Segment total weight:48.18t 3255 1 2 0 0 m m 17700mm 46
SUMMARY Assembly of the EPB TBMs (The TBM parts lowered down and fixed together in the following sequences) Front shield Cutter head(cutting wheel) Middle shield (Main drive unit) Erector Screw conveyor Tail skin
LAUNCHING OF EPM Once the machine is set at correct location, reaction beams will be assembled in the place and backup systems (bridge+gantries) are to be placed on the ground level. S.No. EQUIPMENT NAME UNITS 01 EPB TBMs & THEIR BACKUPs (HERRENKNETCH) 02 02 SEGMENT CARS 08 03 LOCOMOTIVES 04 04 MUCK CARS 16 (12m 3 ) 05 DRAINAGE SYSTEM 02 06 VENTILATION SYSTEM 02 07 GANTRY CRANES 02(35t&10t) 08 MUCK DISPOSAL YARD 865m 3 09 GROUTING PLANT 01 10 GENERATORS 08(500KVA EACH) 11. CHILLING PLANT 01 47
With the above system the TBM will move forward with auxiliary concrete segments between shields jacks and the reaction.When diaphragm will broken out then below mentioned procedure will be followed :- 1. Installation of pump well and dewatering system Pipeline classification Loop drainage (cooling, Water out 4) a. Water in 4 b. Water out 4 c. Grouting pipe 3 d. Grouting pipe 2 2. Fore polling around crown of the EPB machine at the portal 3. Breakout diaphragm wall unit as soon as each unit is completed, concrete on The excavation surface and then place back with lean concrete. This process is again repeated. INITIAL DRIVE After completing the above mentioned preliminary works the machine will make a initial drive .The initial drive is the tunnel excavation for the first 50 to 60 rings of lining into the ground to allow all the backup gantries to move into the tunnel from the working shaft. This process takes about 3 weeks with an average process rate of 3 rings per day(24 hours). During this period, excavated soil in the muck bucket will be directly lifted to the ground level with a gantry crane for dumping excavated soil into the muck pit. Segments will be also feed to the tunnel face by the same gantry crane. gaskets and hydrophilic sealers are to be attached to each segment at the ground level before feeding them to the bottom of the shaft. The back fill systems including grouting materials will be mixed at the ground level and this mixture will be pumped into the void between outer face of the segments and the surrounding grout with gel acceleration agent. Hardening of the mixture depends upon the quantity of the gel to be added and it depends upon actual ground condition .Its range 48
may be 20 seconds to a few minutes. After this secondary grouting also takes place as per the requirement here we done the secondary grouting once using MAI 400 PUMPS. Foam injection system is applied when the conditioning require for the excavated material in chamber to establish enough pressure to support soil face from collapsing while the advancement of EPB machine. The foam container is kept between grouting display panel and bentonite tank. From the tank it is sent by the pump through and it is sent to the face to connect with the foam injection system directly to the various locations
MAIN DRIVE After completion of the initial drive,The reaction rings removed. The main drive will be commenced with an average process of 10 rings per 24 hours operation. The expected monthly is 300 meters. Based on the working shaft space one ring of excavation will used two sets of rolling stocks Two sets of rolling stocks are adapted,namely the one consists of one locomotive,two muck cars, one segment car and the other consists of one muck car, one locomotive and one segment car. The muck buckets lifted up one by one filled with excavated material and first dumped in the muck pit and then it sent to out of the site in the night due to traffic reasons.
ARRIVAL OF MACHINE NEAR RETRIVAL SHAFT When the EPB machine comes close to the diaphragm wall near the retrieval shaft. Then after broken out of the diaphragm wall fore polling is done around the crown of the EPB at the portal. The diaphragm wall braking takes place unit by unit. Then brought the retrieval cradle assembly to retrieve the machine.
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DISMANTLE OF AN EPB MACHINE When the shield arrived the dismantle of the machine started First of all the conveyor belt removed then screw conveyor, removal of cutter head, tail skin and erector , main body, main drive unit respectively.
CROSS PASSAGES CONSTRUCTION To construct a cross passage located between two stations the steel segmental lining used. According to the new drawing there will be cross passages between both the stations and out of five one will be along with drainage system. After completion of all the processes required for the tunneling, the finishing work of the tunnel started
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RAIL PREPARATION FOR THE METRO RAILS After completion of the tunneling work the civil team fills the tunnel by almost 25% for the railways works to run the metro trains.
fig: how the tunnels looks just before rail preparation work. TYPES OF TUNNEL BORING TYPES MACHINES (TBMs) 1. EPB TBMs (Fast tunneling technology with a broad application range) For soft, cohesive soils tunnel boring machines with earth pressure support are a preferred option. So called Earth Pressure Balance Shields (EPB) turn the excavated material into a soil paste that is used as pliable, plastic support medium. This makes it possible to balance the pressure conditions at the tunnel face, avoids uncontrolled inflow of soil into the machine and creates the conditions for rapid tunneling with minimum settlement.
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STABILITY THROUGH FACE SUPPORT PRESSURE The special feature of Earth Pressure Balance Shields is that they use the excavated soil directly as support medium. This method is the first choice in cohesive soils with high clay and silt contents and low water permeability. A rotating cutting wheel equipped with tools is pressed onto the tunnel face and excavates the material. The soil enters the excavation chamber through openings, where it mixes with the soil paste already there. Mixing arms on the cutting wheel and bulkhead mix the paste until it has the required texture. The bulkhead transfers the pressure of the thrust cylinders to the pliable soil paste. When the pressure of the soil paste in the excavation chamber equals the pressure of the surrounding soil and groundwater, the necessary balance has been achieved. CONDITIONS FOR APPLICATION & DIA RANGE OF EPB TBM
FIGURE- SCHEMATIC CROSS SECTIONAL DRAWING OF A TBM
MAIN BEARING CUTTER HEAD
FRONT SHIELD MIDDLE SHIELD
TAIL SKIN
FOAM LINE(4)
MOTORS (8)
SCREW CONVEYOR
SEGMENTFEEDER ERECTOR
MAIN LOCK
THRUST CYLINDERS(32)
CONVEYOR BELT & ACCESSORIES
COPPER WIRE BRUSH(3)
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ADVANTAGES OF EPB SHIELD TBM: -- Very high and consistent advance rates possible in cohesive soils with high clay or silt content -- Geological range of application can be enhanced by soil conditioning --No additional support medium required --A range of special solutions available for heterogeneous soil conditions SCREW CONVEYOR SPEED AND TBM ADVANCE RATE REGULATES THE PRESSURE CONDITIONS IN THE TBMs A screw conveyor transports the excavated material from the base of the excavation chamber onto a belt conveyor. The interaction between the screw conveyors throughput and the TBMs advance rate ensure that the support pressure of the soil paste can be controlled precisely. The balance in the excavation chamber is continuously monitored using earth pressure sensors. In this way, the TBM operator is able to fine-tune all tunneling parameters to each other even under changing geological conditions, allowing for high advance rat rates and minimizing the risk of heave or settlement at the surface.
FIG:-HOW THE PRESSURE BALANCED IN THE IN TBM CHAMBER 54
ADVANTAGES OF EPB TBM -- Very high and consistent advance rates possible in cohesive soils with high clay or silt content -- Geological range of application can be enhanced by soil conditioning -- No additional support medium required -- A range of special solutions available for heterogeneous soil conditions WIDER APPLICATION RANGE THROUGH PERFECT SOIL CONDITIONING Not all ground conditions have ideal characteristics for EPB tunnelling in their natural state. However, the application range of this method can be enhanced tremendously by soil conditioning. This means changing the plasticity, texture and water permeability of the soil by injecting various conditioning materials such as water, bentonite or foam. This allows EPB Shields to achieve good advance rates even in heterogeneous soils containing gravel, sand or water, or in unstable geological conditions.
NEW DEVELOPMENTS FOR LARGE DIMENSIONS 55
New developments for large dimensions of TBMs and their different mode operation 2. MIXED SHIELD (Safe tunneling technology for heterogeneous ground)- The Mixed shield technology developed by Herrenknecht is an advance on conventional slurry technology. The support pressure in the Excavation chamber is precisely managed using an automatically controlled air cushion. This means that heterogeneous geologies and high water pressures of more than 15 bar can be controlled safely even with very large excavation diameter
HIGH SAFETY DUE TO AIR PRESSURE A characteristic feature of mixed shields is an excavation chamber that is divided by a so- called submerged wall. The front section of the excavation chamber is completely filled with suspension for full tunnel face support during tunneling. In the rear section between submerged wall and bulkhead (working chamber) the suspension reaches up to only just above the machine axis. The counter-pressure needed at the tunnel face is supplied using a compressible air cushion in the upper section. Communication between the two chambers takes place through a submerged wall opening in the invert section. MIXED SHIELD TBM 56
Fully-automated control circuits permanently monitor pressure conditions and ensure considerably more precise pressure control than in conventional one-chamber systems. Decoupling the circulating suspension from support pressure control provides for higher flexibility and safety during tunneling. Since it is possible to react directly through the air cushion, even small pressure and volume fluctuations in heterogeneous geologies can be controlled exactly. This allows for much better control in terms of heave and settlement, which must be avoided, especially with small overburdens
SEALING AGAINST HIGH WATER PRESSURES Mixed shields can be used safely even with high water pressures of more than 15 bar due to their closed hydraulic slurry circuit. However, this requires a sealing layer between the machine and the ground to be excavated. This is why Mixshields are equipped with a multiple sealing system. The main drive seal is designed as a system with individual sealing chambers containing pressurized sealant. At the rear of the machine, the annular gap between the inside of the tail skin and the outside of the segment lining is sealed with multiple wire brushes to keep out the soil and groundwater.
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CROSS SECTIONAL VIEW OF MIXED SHIELD TBM
Figure- Cross Sectional View Of Mixed Shield TBMs CONVEYING TO MEASURE Jaw crushers (left) and drum crushers with agitators (right) crush boulders or stones during tunneling. In typical Mixed shield tunneling operations in cohesive, heterogeneous soils, larger stones or blocks must be expected. Such boulders need to be crushed to a conveyable size so that hydraulic removal can be carried out smoothly. Mixed shields often use a jaw crusher for this purpose, which is positioned in front of the intake screen. The size of the crushable stones varies according to the design of the crusher and the shield diameter. In addition, an intake screen is installed in front of the suction port of the slurry line to protect the machine against grain sizes that might cause problems. It holds up boulders until the crusher has crushed them sufficiently. If there are fine-grained, cohesive soils along the alignment, drum crushers are installed in front of the intake as an alternative. 58
They carry out the intake screen function during the crushing process. Two lateral agitators support the flow of material in the invert section.
Figure:-INSIDE VIEW OF CRUSHING CHAMBER
CONDITIONS FOR APPLICATION & DIA RANGE OF MIXED SHIELD TBM
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ADVANTAGES OF MIXED SHIELD TBM -Maximum tunneling safety due to precise support of the tunnel face with an automatically controlled air cushion -Usable in high water pressures of more than 15 bar -Even very large diameters of up to 19 m possible -A range of special solutions available for special project requirements
SINGLE SHIELD TBM (Fast tunneling in changing rock conditions) Single Shield TBMs are the ideal machine type for tunneling through rock and other stable, non-groundwater-bearing soils. Due to the typical tunneling methods with segmental lining or pipe jacking, high tunneling performances can also be achieved in rock formations with low stand-up times.
SINGLE SHIELD TUNNEL BORING MACHINE 60
ADVANCING WITH POWER When tunneling with a Single Shield TBMs, a rotating cutter head equipped with disc cutters is pressed against the tunnel face with a pressure of up to tones per disc. Due to the rolling movement of the discs, single pieces so-called chips are broken out of the rock. Water jets can cool the cutting tools and reduce dust formation. Buckets installed at the cutter head take up the excavated material. Thanks to gravity, it slides to the center of the machine through integrated muck chutes while the cutter head rotates and then falls through the funnel-shaped muck ring onto the machine belt. At the end of the machine belt, the rock chips are passed on to belt conveyors or transport vehicles and removed from the tunnel. CONDITIONS FOR APPLICATION & DIA RANGE OF SINGLE SHIELD TBM
CROSS SECTIONAL VIEW OF SINGLE SHIELD TBM 61
ILLUSTRATION HOW THE EXCAVATED SOIL COMES OUT 62
DOUBLE SHIELD TBM(Continuous tunnelling at maximum speed) Double Shield TBMs are among the most technically sophisticated tunnel boring machines. They unify the functional principles of Gripper and Single Shield TBMs in one machine. Under stable geological conditions, the combination of methods allows for the installation of concrete segments parallel to tunnelling, achieving very high tunnelling performances. This powerful technology is therefore perfectly suited for excavating long tunnels in hard rock.Advancing with power. When tunnelling with a Double Shield TBM, a rotating cutterhead equipped with disc cutters is pressed against the tunnel face with a pressure of up to 32 tonnes per disc. Due to the rolling movement of the discs, single pieces so-called chips are broken out of the rock. Water jets can cool the cutting tools and reduce dust formation. Buckets installed at the cutterhead take up the excavated material. Due to gravity, it slides to the center of the machine through integrated muck chutes while the cutterhead rotates and then falls through the funnel-shapedmuck ring onto the machine belt. At the end of the machine belt, the rock chips are passed on to belt conveyors or transport vehicles and removed from the tunnel.
CONDITIONS FOR APPLICATION & DIA RANGE OF DOUBLE SHIELD TBM
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CROSS SECTIONAL VIEW OF DOUBLE SHIELD TBM
HIGH SPEED DUE TO A CONTINUOUS TUNNELLING MODE Double Shield TBMs consist of two main components: a front shield with cutterhead, main bearing and drive, and a gripper shield with gripping unit, auxiliary thrust cylinders andtailskin. The main thrust cylinders connect the two parts of the shield. They are protected by the telescopic shield where the shield skins of the front and gripper shield overlap. Thus, Double Shield TBMs are also called telescopic shields. In stable rock, the machine is braced radially against the tunnel with the gripper shoes. This means that the front shield can be advanced independently of the gripper shield using the main thrust cylinders. The reaction forces during the excavation process are transferred into the rock by the extended gripper shoes. Simultaneously to tunnelling, the segments are installed in the tailskin section. The auxiliary thrust cylinders serve only to secure the position of the concrete segments placed. When the stroke is completed, the gripper shoes are loosened 64
and the gripper shield is pushed behind the front shield using the auxiliary thrust cylinders. Regripping lasts only a few minutes, which means that tunnelling is almost continuous. In ideal rock formations, Double Shield TBMs can also operate without segment lining.
A movable telescopic shield provides for access to the tunnel wall during cleaning work in Double Shield TBMs. GRIPPER TBM(Experts for tough hard rock)
Herrenknecht Gripper TBMs have proven to be efficient solutions for fast mechanized tunnelling in hard rock on many occasions. Due to the process-typical rock support method without segments, medium to high rock strengths ggare a requirement for high advance rates. In more fractured geological formations, various systems for immediate rock support behind thge cutterhead are installed at the TBM directly.
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CROSS SECTIONAL VIEW OF THE GRIPPER TUNNEL BORING MACHINE
UNCOMPROMISING IN HARD ROCK Tunnelling with a Gripper TBM, a rotating cutterhead equipped with disc cutgters is pressed against the tunnel face with a pressure of up to 32 tonnes per discg. Due to the rolling movement of the cutter, single pieces so- called chips are broken out of the rock. Water jets can cool the cutting tools and reduce dust formation. Buckets installed at the cutterhead take up the excavated material, which slides to the center of the machine via integrated muck chutes while the cutterhead rotates, and then falls through the funnel- shaped muck ring onto the machine belt. From there, the rock chips are passed on via further belt conveyors or transport vehicles and removed from the tunnel. The rock is secured by anchors, steel mats and steel arches as well as shotcrete.
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CONDITIONS FOR APPLICATION & DIA RANGE OF DOUBLE SHIELD TBM
PARTIAL-FACE EXCAVATION MACHINE (Economical tunneling technology with high flexibility) Partial-face Excavation Machines made by Herrenknecht are an economically interesting solution in homogeneous and almost stable grounds with little or no groundwater. This tunneling technology can be easily adapted to changing geological conditions both in loose soils and in hard rock due to its strikingly simple design.
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Here both the machines are same but the tool being used for cuuting the material are dfferent
Fig:-Cross sectional view of partial face excavation machine 68
ONE MACHINE, TWO EXCAVATION METHODS Herrenknecht shields with partial-face excavation can excavate the soil with two different cutting tools. In loose soils, the excavator has proved its great value hundreds of times. The universal excavator boom is equipped with a shovel, a ripper tooth or a hydraulic jackhammer depending on the soil conditions. Roadheader booms are used in harder rock with uniaxial compressive strengths of up to 80 megapascal. Both boom technologies allow quick and easy replacement of the worn tools. The excavated material is transported by belt conveyors or chain conveyors to the conveying system in the back. The application range of Partial-face Excavation Machines starts at around 1.5 meters, as it is necessary to access the tunnel. Tunnelling operations with diameters of more than 10 meters can be carried out cost effectively using additional support measures or grout injections to improve the ground. Conditions For Application & Dia Range Of Double Shield TBM
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OTHER TUNNELING MACHINES
AUGER BORING MACHINETOP FOR SHORT DRIVES
Auger Boring Machines are used for the successful installation of sewage ducts and pipelines and for crossings beneath infrastructures. The boring machines offered by Herrenknecht in cooperation with Bohrtec GmbH stand out in comparison to conventional construction methods due to their technical, economic and ecological advantages. Their main range of application is underground pipe jackingwith comparatively small diameters, from 0.1 to 1.4 meters with drive lengths of up to 120 meters.
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CONDITIONS FOR APPLICATION & DIA RANGE OF AUGER BORING
HDD RIG (Powerful horizontal directional drilling technology for trenchless pipeline installation) With horizontal directional drilling technology from Herrenknecht, pipelines can be installed rapidly, economically and with little to no impact on the environment underneath rivers and other obstructions. HDD Rigs are highly adaptable and used mainly in stable, loose soils and rock. 71
The Three Basic Steps in HDD Pilot drill Reaming Pipelineinstallation CONDITIONS FOR APPLICATION & DIA RANGE OF HDD
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DIRECT PIPE (Pipeline installation in one step)
With the unique Direct Pipe
technology, Herrenknecht has opened up new possibilities
for installing pipelines in every geology.This method combines the advantages of micro tunneling and HDD technology. In one step only, a prefabricated pipeline can be installed and the required borehole excavated at the same time. This allows speedy and highly economic installation of pipelines with lengths of more than 1,500 meters.
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Cross sectional view of the direct pipe machine
CONDITIONS FOR APPLICATION & DIA RANGE OF DIRECT PIE TBM VERTICAL SHAFT SINKING MACHINE (VSM) (Compact shaft sinking technology for all ground conditions) For quick and reliable construction of vertical shafts, Herrenknecht developed its VSM (Vertical Shaft Sinking Machine) technology, today an established product on the market. This unique mechanized shaft sinking equipment shows its strengths particularly below groundwater. In general, it can be used in soft and stable soils with compression strengths of up to 80 mega pascal. CROSS SECTIONAL VIEW OF THE VSMs 74
CONDITIONS FOR APPLICATION & DIA RANGE OF VSMs
2. THE DEPARTMENTS INVOLVE IN STRUCTURAL FABRICATION (a)PLANNING (b)EXECUTION (c)QUALITY (d)SAFETY
2(a) PLANNING:- DEVELOPMENT OF CONSTRUCTION PLANS: - Construction planning is a fundamental and challenging activity in the management and execution of construction projects. It involves the choice of technology, the definition of 75
work tasks, the estimation of the required resources and durations for individual tasks, and the identification of any interactions among the different work tasks. A good construction plan is the basis for developing the budget and the schedule for work. Developing the construction plan is a critical task in the management of construction, even if the plan is not written or otherwise formally recorded. In addition to these technical aspects of construction planning, it may also be necessary to make organizational decisions about the relationships between project participants and even which organizations to include in a project. For example, the extent to which sub- contractors will be used on a project is often determined during construction planning. In developing a construction plan, it is common to adopt a primary emphasis on either cost control or on schedule control as illustrated in Fig. Some projects are primarily divided into expense categories with associated costs. In these cases, construction planning is cost or expense oriented. Within the categories of expenditure, a distinction is made between costs incurred directly in the performance of an activity and indirectly for the accomplishment of the project. For example, borrowing expenses for project financing and overhead items are commonly treated as indirect costs. For other projects, scheduling of work activities over time is critical and is emphasized in the planning process. In this case, the planner insures that the proper precedence among activities is maintained and that efficient scheduling of the available resources prevails. Traditional scheduling procedures emphasize the maintenance of task precedence (resulting in critical path scheduling procedures) or efficient use of resources over time (resulting in job shop scheduling procedures). Finally, most complex projects require consideration of cost and scheduling over time, so that planning, monitoring and record keeping must consider both dimensions. 76
Fig.-Alternative emphases in construction planning
CHOICE OF TECHNOLOGY AND CONSTRUCTION METHODS: - As in the development of appropriate alternatives for facility design, choices of appropriate technology and methods for construction are often ill-structured yet critical ingredients in the success of the project. For example, a decision whether to lift the material by machine or manually will directly affect the cost and duration of tasks involved in construction. A decision between these two alternatives should consider the relative costs, reliabilities, and availability of equipment for the two transport methods. Unfortunately, the exact implications of different methods depend upon numerous considerations for which information may be sketchy during the planning phase, such as the experience and expertise of workers or the particular underground condition at a site.
DEFINING WORK TASKS:- At the same time that the choice of technology and general method are considered, a parallel step in the planning process is to define the various work tasks that must be 77
accomplished. These work tasks represent the necessary framework to permit scheduling of construction activities, along with estimating the resources required by the individual work tasks and any necessary precedence or required sequence among the tasks. The terms work "tasks" or "activities" are often used interchangeably in construction plans to refer to specific, defined items of work. In job shop or manufacturing terminology, a project would be called a "job" and an activity called an "operation", but the sense of the terms is equivalent.
ESTIMATING ACTIVITY DURATION: - In most scheduling procedures, each work activity has associated time duration. These durations are used extensively in preparing a schedule. All formal scheduling procedures rely upon estimates of the durations of the various project activities as well as the definitions of the predecessor relationships among tasks. The variability of an activity's duration may also be considered. Formally, the probability distribution of an activity's duration as well as the expected or most likely duration may be used in scheduling. A probability distribution indicates the chance that particular activity duration will occur. In advance of actually doing a particular task, we cannot be certain exactly how long the task will require. A straightforward approach to the estimation of activity durations is to keep historical records of particular activities and rely on the average durations from this experience in making new duration estimates. Since the scopes of activities are unlikely to be identical between different projects, unit productivity rates are typically employed for this purpose.
ESTIMATING RESOURCE REQUIRMENTS FOR WORK ACTIVITIES:- In addition to precedence relationships and time durations, resource requirement are usually estimated for each activity. Since the work activities defined for a project are comprehensive, the total resources required for the project are the sum of the resources required for the various activities. By making resource requirement estimates for each activity, the requirements for particular resources during the course of the project can be identified. Potential bottlenecks can thus be identified, and schedule, resource allocation 78
or technology changes made to avoid problems. Many formal scheduling procedures can incorporate constraints imposed by the availability of particular resources. For example, the unavailability of a specific piece of equipment or crew may prohibit activities from being undertaken at a particular time. Another type of resource is space.
2 (b) EXECUTION:- Execution is the most important part of the structural fabrication Structural engineers are responsible for engineering design and analysis. Entry-level structural engineers may design the individual structural elements of a structure, for example the beams, columns, and floors of a building. More experienced engineers may be responsible for the structural design and integrity of an entire system Structural steel fabrication can be carried out in shop or at the construction site. Fabrication of steelwork carried out in shops is precise and of assured quality, whereas field fabrication is comparatively of inferior in quality. All the work of the structural fabrication is done as per drawing. The fabrication drawing consist all the information regarding fabrication, material connections etc. DRAWING: - Fabrication drawing is a type of technical drawing, is used to fully and clearly define requirements for engineered items. Fabrication drawing (the activity) produces engineering drawings (the documents). More than just the drawing of pictures, it is also a language graphical language that communicates ideas and information from one mind to another. Most especially, it communicates all needed information from the engineer who designed a part to the workers who will make it. MATERIAL: - From reputed sources like SAIL, JSPL&TATA as per approved by engineer and shall conform to the following. Contractor shall use material for fabrication as specified in the approved drawings. All material supplied by the contractor shall be in sound condition of recent manufacturers, free from defects such as loose mill scale, slag inclusions,pitting,flaky rust etc. The length /size of steel section and plate shall be as 79
supplied by the steel mills and conforms to the latest issue of the relevant IS/ASME specification. All material required for the work shall be correlated with manufacturers test certificates. In the absence of test certificate material shall be tested by contractor through an approved laboratory for establishing specification requirements at contractors cost and as directed by the engineers. All tests shall be witnessed by owners representative. The engineer shall have the right to test random samples to prove authenticity of test certificate All structural steel of thickness<20mm is of grade A, All structural steel of thickness>20mm is grade B, for crane girder steel shall meet grade C.
IS: 2062-Steel for general structural purposes specification
CHEMICAL COMPOSITION Grade C % Mn % S % P % Si C. E. % Max. Max. Max. Max. Max. Max. A 0.23 1.5 0.05 0.05 - 0.42 B 0.22 1.5 0.045 0.045 0.04 0.41 C 0.2 1.5 0.04 0.04 0.4 0.39
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MECHANICAL PROPERTIES Grade UTS (MPA) Y.S.(MPA) Min. EI. % Min Bend A Min. < 20 mm 20-40 mm > 40 mm 5.65 So Test B 410 250 240 230 23 3T C 410 250 240 230 23 2T & 3T* 410 250 240 230 23 2T
IS: 808- Dimension for hot rolled steel beams, channels and angle sections
FOREWORD:- This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards on 6 April 1989, after the draft finalized by the Structural Sections Sectional Committee had been Approved by the Structural and Metals Division Council. Under the steel economy programmed, a rational, efficient and economical series of Indian Standards on beam sections, channel sections and angle sections was evolved in 1957 and IS 808 : 1957 was published covering junior, light weight, medium weight, wide flange and heavyweight beam sections; junior, light weight and medium weight channel sections and equal and unequal leg angle sections. This standard was revised in 1964.In the second revision of this standard, parts relating to medium weight beam sections MB series, column sections SC series, channel sections MC and MCP series and equal and unequal leg angles were revised and published as Parts 1, 2, 3, 5 and 6 of IS 808, respectively. Sections not 81
covered in these parts, however continued in IS 808: 1964.In the present revision, the Sectional Committee felt it convenient to merge the entire five parts into one standard. The sections which were retained in IS 808: 1964 subsequent to its second revision in five parts are included in this standard with a view that these sections although not being rolled in the country at present may in future be rolled owing to their efficiency and resultant economy in the use of steel. However, the designers are advised to check from JPC/producers regarding availability of such sections. Following additional modifications have been affected in this revision: MATERIAL CUTTING:- Every successful manufacturing company must plan the efficient use of raw material. This planning has many facets and implications. In a custom-product make-to-order industry, material plans can impact customer service, the accuracy and speed of cost estimation, and possibly the firm's ability to secure contracts. In every industry it has a fundamental influence on cost and Processing needs. This dissertation focuses on a firm's ability to purchase raw material in bulk and subsequently to divide and process it. The problem shares general characteristics with well known problems such as cutting stock problems, cluster problems and grouping problems. Many of the models and solution techniques for these related problems are useful starting points for this research but none of them provide an acceptable approach to the problem of interest. This chapter provides an overview of the problem of interest, the cutting plan generation or CPG problem. It describes the CPG problem in the context of other operations research models and techniques. The scope of this research is also discussed.
OVERVIEW OF CUTTING PLAN GENERATION (CPG):- In the steel construction industry, preparing and ordering raw material is crucial to the efficiency and control of cost within the whole process operation. The cost of raw material may constitute 45% to 60% of the total cost (Huang 1998). Raw material is ordered in bulk to get volume discounts or to avoid extra costs applied to small orders. In ordering raw material, a crucial design operation is generating the "cutting plan" that 82
specifies the details of the order and how the production operations will use the steel to construct the building. The cutting plan is important because it links architectural design, material preparation, manufacturing, and final assembly. The following sections explain the background of cutting plan generation in the steel construction industry and the motivation for this research.
CUTTING PLAN:- As discussed above, cutting plan generation is the central process in the detailed design phase. It provides information that impacts all aspects of operations such as marketing, pricing, cost, production and material ordering. It is important to generate a cost saving cutting plan in a timely fashion so that the whole system can be synchronous and efficient. As the material costs make up most of the project cost, a small improvement in the cutting plan generation process can lead to a significant cost savings and a competitive advantage. However, cost is not minimized simply by minimizing material waste. The unit cost of raw material varies with the width of the plate ordered, in addition to other factors. Often, the material unit cost increases for both small and large sizes so a construction company must attempt to group its material requirements to achieve plates that have a width between the bounds defining the lowest unit cost. Since the steel plates can be ordered in any desired size within a range, the need to address material waste is a secondary factor. Minimize material and design labor cost. Reduce necessary lead-time in material ordering. Improve project cost estimation that would enable timely analysis and evaluation of different design alternatives so that project bidding can reflect more accurate cost figures. Speed the detail design process so that architects can generate more design alternatives early in the design stage. Estimate the impact of uncertainty in various parameters so that contingency plans can be developed. Monitor production and provide feedback for continuous improvement 83
MAJOR EQUIPMENT USED AT AZADPUR JOB SITE :- Crane Gas cutting apparatus Grinding machine H Beam assembler Welding machine Portable drilling machine Miscellaneous tools
CRANES:- A crane is a type of machine, generally equipped with a hoist, wire ropes or chains, and sheaves, that can be used both to lift and lower materials and to move them horizontally. It is mainly used for lifting heavy things and transporting them to other places. It uses one or more simple machines to create mechanical advantage and thus move loads beyond the normal capability of a human. Cranes are commonly employed in the transport industry for the loading and unloading of freight, in the construction industry for the movement of materials and in the manufacturing industry for the assembling of heavy equipment.
TYPES:- OVERHEAD CRANE:- An overhead crane, commonly called a bridge crane, is a type of crane found in industrial environments. An overhead crane consists of parallel runways with a traveling bridge spanning the gap. A hoist, the lifting component of a crane, travels along the bridge. If the bridge is rigidly supported on two or more legs running on a fixed rail at ground level, the crane is called a gantry crane. Unlike mobile or construction cranes, overhead cranes are typically used for either manufacturing or maintenance applications, where efficiency or downtime is critical factors. 84
MOBILE CRANE:- The most basic type of mobile crane consists of a truss (lattice boom) or telescopic boom mounted on a mobile platform be it on road, rail or water. Common terminology is conventional and hydraulic cranes respectively. A crane mounted on a truck carrier provides the mobility for this type of crane. This crane has two parts: the carrier often referred to as the Lower, and the lifting component which includes the boom, referred to as the Upper. TOWER CRANE:- Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to the ground on a concrete slab (and sometimes attached to the sides of structures as well), tower cranes often give the best combination of height and lifting capacity and are used in the construction of tall buildings. The base is then attached to the mast which gives the crane its height. Further the mast is attached to the slewing unit (gear and motor) that allows the crane to rotate.
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TALISCOPIC BOOM CRAWLER CRANE (FIXED BOOM) 86
GRINDING MACHINE:- A grinding machine, often shortened to grinder, is a machine tool used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear deformation. Grinding is used to finish work pieces that must show high surface quality (e.g., low surface roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some roughing applications in which grinding removes high volumes of metal quite rapidly. Thus, grinding is a diverse field. The main type of grinding machine is used for fabrication is angle grinder.
ANGLE GRINDER: - An angle grinder, also known as a side grinder or disc grinder is a handheld power tool used for cutting, grinding and polishing. Angle grinders can be powered by an electric motor, petrol engine or compressed air. The motor drives a geared head at a right-angle on which is mounted an abrasive disc or a thinner cut-off disc, either of which can be replaced when worn. Angle grinders typically have an adjustable guard and a side-handle for two-handed operation. Certain angle grinders, depending on their speed range, can be used as sanders, employing a sanding disc with a backing pad or disc. The backing system is typically made of hard plastic, phenol resin, or medium-hard rubber depending on the amount of flexibility desired
USES: - Angle grinders may be used both for removing excess material from a piece or simply cutting into a piece. There are many different kinds of discs that are used for various materials and tasks, such as cut-off discs (diamond blade), abrasive grinding discs, grinding stones, sanding discs, wire brush wheels and polishing pads. The angle grinder has large bearings to counter side forces generated during cutting, unlike a power drill, 87
where the force is axial. Angle grinders are widely used in metalworking and construction, as well as in emergency rescues. They are commonly found in workshops, service garages and auto body repair shops. There is a large variety of angle grinders to choose from when trying to find the right one for the job. .
H BEAM ASSEMBLER:- H-beam Assembly-Welding-Straightening Integrating machine is advanced and high efficiency equipment for welding H-beam production, integrating precision assembly, and stable SAW welding, flange deformation straightening and welding of H-beam 88
together. It has merits of compact structure, small area occupying, high automatic and high productivity. It mainly consists of assembly unit welding unit straightening unit conveyor hydraulic system and electrical control system, etc.
FABRICATION: - Structural steel fabrication can be carried out in shop or at the construction site. Fabrication of steelwork carried out in shops is precise and of assured quality, whereas field fabrication is comparatively of inferior in quality. In India construction site fabrication is most common even in large projects due to inexpensive field labor, high cost of transportation, difficulty in the transportation of large members, higher excise duty on products from shop. Beneficial taxation for site work is a major financial incentive for site fabrication. The methods followed in site fabrication are similar but the level of sophistication of equipment at site and environmental control would be usually less SEQUENCE OF FABRICATION:- Before issuing for fabrication, all materials is inspected & correlated with test certificate. After inspection, material is issued and shifted to fabrication shop. All surfaces are cleaned prior to fabrication & mill scales is removed during painting. Before cutting heat number is transferred to corner of the plate. Required straightening, bending is carried out by mechanical means of James screw and Jigs &fixture. Platform/assembly bed with sufficient coverage area is prepared of required size for fabrication purpose. Fabrication of plate for column is cut in a designated area of fabrication shop. Plates are check for visual defects prior to cutting. 89
Cutting is done by manual gas cutting/pug cutting. During cutting care will be taken to avoid distortion. Ensure periodic calibration of welding machine/ovens and qualification of welders. Adequate protection from rain & wind will be provided during welding. All parts to be welded is cleaned off rust and other foreign materials that may affect welding process. Preheating at 121 0 c is applied whenever material has maximum carbon content is more than 0.3% and thickness is exceed 20mm. All slag and spatters is removed from the welding area after completion of welding, PWHT will be carried out as per procedure. Dimension of all assembly and sub assemblies will be as per approved fabrication drawing. Elevation and part no. will be match marked at both ends of all fabricated structural members for proper identification during erection. After removing the temporary attachment, NDT test wherever applicable will be performed on the attached components & the QC inspector will ensure each item is properly punched with identification prior to release for blasting / painting. Grit blasting & painting will be carried out as per approved drawing / specification. DFT will be checked after complete drying of paint & will be as per approved drawing. Fabricated structures will be stocked and stored under cover at fabricated material area.
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2(c) QUALITY:- QA/QC is the combination of quality assurance, the process or set of processes used to measure and assure the quality of a product, and quality control, the process of meeting products and services to consumer expectations. QUALITY ASSURANCE (Q/A): - QA is a set of activities for ensuring quality in the processes by which products are developed. It aims to prevent defects with a focus on the process used to make the product. It is a proactive quality process. The goal of QA is to improve development and test processes so that defects do not arise when the product is being developed. Establish a good quality management system and the assessment of its adequacy. Periodic conformance audits of the operations of the system. Prevention of quality problems through planned and systematic activities including documentation. Everyone on the team involved in developing the product is responsible for quality assurance. QUALITY CONTROL (Q/C): - QC is a set of activities for ensuring quality in products. The activities focus on identifying defects in the actual products produced. QC aims to identify (and correct) defects in the finished product. Quality control, therefore, is a reactive process. The goal of QC is to identify defects after a product is developed and before it's released Finding & eliminating sources of quality problems through tools & equipment so that customer's requirements are continually met. The activities or techniques used to achieve and maintain the product quality, process and service. Quality control is usually the responsibility of a specific team that tests the product for defects.
INSPECTION:- VISUAL INSPECTION:- Visual inspection is a common method of quality control, data acquisition, and data analysis. Visual Inspection, used in maintenance of facilities, mean inspection of equipment and structures using either or all of raw human senses such as vision, hearing, 91
touch and smell and/or any non-specialized inspection equipment. In this the quality person inspects the job without using any equipment. The visible defect can be easily detected by this method. The experience of the person is very important in the visual inspection. INSPECTION STEPS:- PRE-CLEANING:- The test surface is cleaned to remove any dirt, paint, oil, grease or any loose scale that could either keep penetrant out of a defect, or cause irrelevant or false indications. Cleaning methods may include solvents, alkaline cleaning steps, vapor degreasing, or media blasting. The end goal of this step is a clean surface where any defects present are open to the surface, dry, and free of contamination. Note that if media blasting is used, it may "work over" small discontinuities in the part, and an etching bath is recommended as a post-blasting treatment
(d) SAFETY:- An industrial safety system is a countermeasure crucial in any hazardous plants such as oil and gas plants and nuclear plants. They are used to protect human, plant, and environment in case the process goes beyond the control margins. As the name suggests, these systems are not means of process control systems (PCS) and is interlocked by the safety systems so that immediate actions are taken should the process control systems fail. Process control and safety systems are usually merged under one system JOB HAZARD ANALYSIS:- A Job Hazard Analysis (JHA) is one of the risk assessment tools used to identify and control workplace hazards. A JHA is a second tier risk assessment with the aim of preventing personal injury to a person, or their colleagues, and any other person passing 92
or working adjacent, above or below. JHAs are also known as Activity Hazard Analysis (AHA), Job Safety Analysis (JSA) and Task Hazard Analysis (THA).
PURPOSE:- The purpose of a JHA is to identify workplace hazards with a 'Likelihood' of possible or greater. Controls are then selected and applied to reduce the risk associated with the identified hazards to acceptable levels in accordance with the principles of 'ALARP' and using the 'Hierarchy of Control'.
WORK PLACE HAZARD CRITERION:- The criterion is a set of standards to assist in deciding to include, or exclude, certain identified hazards related to our task. The workplace hazard criterion used to identify genuine workplace hazards is: It is clearly identifiable - Clearly identifiable means that we are specific about the hazard to the point where the hazard type, group and family are instantly linked to it. A scenario is not required for its articulation - It can be clearly described in five, or less, words. If you cannot, it probably is not a hazard. It has an inherent likelihood of possible or greater - If the hazard you are applying the criteria to does not have an inherent likelihood of Possible, or greater, then drop it and move on. It is without judgmental adjectives - Judgmental adjectives are negative and sometimes overlap with descriptions of absence. Adjectives such as poor, deficient, defective, scant, weak, unsound, faulty are not to be used in the hazard column. It contains no descriptions of absence - Descriptions of absence are usually negative and sometimes overlap with Judgmental adjectives. They include: Without, lack of, minimal, unsuitable, unavailable, inadequate, missing, and non- 93
existent. CONSEQUENSES:- Consequence is the outcome of an event expressed qualitatively or quantitatively, being a loss, injury, disadvantage or gains. There may be a range of possible outcomes associated with an event. Consequence consists of two factors. The first is the mechanism of injury covered above. The second factor is the estimation of the severity of the injury or harm that can be reasonably and realistically expected from exposure to the obvious mechanism of injury of the hazard being rated. The consequence is quantified using a severity of consequence scale. It is acknowledged that an implemented control may lower the severity of the injury, it may also increase it, either way, it has no effect on the way the injury occurred. Therefore, when rating risk, the consequence remains the same for both the initial rating and the residual rating. People inherently lean toward a higher than actual consequence when rating risk, so remember to apply the rule of being reasonable and realistic.
REASONABLY PRACTICABLE:- Reasonably practicable, in relation to a duty to ensure health and safety, means that which is, or was at a particular time, reasonably able to be done to ensure health and safety, taking into account and weighing up all relevant matters including: the likelihood of the hazard or the risk concerned occurring; and the degree of harm that might result from the hazard or the risk; and what the person concerned knows, or ought reasonably to know, about the hazard or risk, and about the ways of eliminating or minimizing the risk; and the availability and suitability of ways to eliminate or minimize the risk; and After assessing the extent of the risk and the available ways of eliminating or 0minimizing the risk, the cost associated with available ways of eliminating or minimizing the risk, including whether the cost is grossly disproportionate to the risk. 94
CONCLUSION In the field of TUNNELING the Continental Engineering Corporation. has diverse, world class, design and engineering. In India most raw materials and inputs are brought from SAIL, JINDAL and TATA. Transportation costs are a major concern for CEC CICI JV in remaining competitive in the India and international markets. Efficient modes of transportation, including road and rail, are very important for the timely movement of goods, especially larger non-containerized types of products. The fabrication sector is dependent on the continuing supply of skilled workers, preferably from local sources, in order to maintain the level of productivity and quality of finished goods. Here in Delhi Metro the industry is dependent upon DMRCs plan and their higher quality of programs. The main execution of work is based on the planning and the tunneling. There are two types of works Delhi Metro tunneling and station work. Tunneling is totally based on the TBMs which bore the tunnel through the soil below the city surface and station work is based on Fabrication drawing which shows the dimensions and holes whereas detailed drawing shows the connections of the column and beams. The quality assurance is totally depends on skill of manpower and QA/QC engineer.
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